BAJA SAE Suspension System

What?

Designed and optimized the suspension system for an SAEINDIA m-BAJA all-terrain vehicle (ATV) for the 2017-18 competition.
Focused on improving stability, maneuverability, durability, and off-road performance under extreme terrain conditions.
Developed independent suspension with double wishbone geometry for the front and H-arm with camber link for the rear.

How?

Suspension Geometry: Designed a double-wishbone front suspension for better camber control and an H-arm with camber link at the rear for improved traction and wheel travel.
Material Optimization: Used AISI 4130 steel for wishbones and camber links, and EN24 steel for bearing housings to balance strength and weight.
Performance Tuning: Optimized camber change rate, kingpin inclination, caster angle, and roll stiffness, and set spring rates (Front: 11.93 N/mm, Rear: 21.72 N/mm) for handling and stability.
Analysis & Validation: Conducted FEA and Multibody Dynamics (MBD) simulations to validate stress distribution, load forces, and suspension kinematics.

Result

Optimized Suspension Dynamics: Achieved ride frequency (Front: 1.806 Hz, Rear: 2.21 Hz) for better ride quality and terrain adaptability.
Weight Reduction & Durability: Successfully integrated AISI 4130 components, ensuring a strong yet lightweight structure.

Pawan Sawant